Method and apparatus for producing carbom



June 12, E923.

c.- MATLOQK METHOD AND APPARATUS FOR PRODUCING CARBON Filed Jan 5, 1921 2 Shee ts-Sheet 1 avwamtoz June 12, I923. 1,458,351

C. MATLOCK 0 METHOD AND APPARATUS FOR PRODUCING CARBON Filed Jan. 5, 1921 2 Sheets-Sheet '2 patented lune 312, i923.

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CHAUNCEY MATLOCK,

CARBON COMPANY, OF MONROE,

OF BROOKLYN, NEW YORK, ASSIGNOR TO MONROE-LOUISIANA LOUISIANA, A CORPORATION OF DELAWARE.

METHOD AND APPARATUS FOR. PRODUCING CARIBOliTK3 sure Application filed January 5, 1921. Serial No. 435,071.

To all whom it may concern:

Be it known that I, CHAUNCEY MATLOCK, residing at 207 Park Place, Brooklyn, county of Kings, State of New York, have 4 5 invented certain new and useful Improvements in Methods" and Apparatus for Producing Carbon. of which I declare the following to be a full, clear, and exact description.

This invention relates to the disassociation of the constituents of hydrocarbons and particularly to the disassociation of a hydrocarbon gas and the collection and recovery of the elemental carbon therefrom.

The object of my invention generally to obtain an improved quality of carbon black from a hydrocarbon gas, natural gas, and to recover a larger proportion of the carbon constituent per unlt volume. of gas than has hitherto been possible with many known methods and devices.

A further object of my invention is a method and an apparatus for producm carbon black whereby the cost of instal ation and operation of the plant are reduced to a minimum and the efliciency of production generally improved, the operation according to this method, being continuous and non-intermittent.

The method and apparatus generally used for producing carbon black on a commercial scale consists in partially burning the natural gas or other hydrocarbon gas by means of a multiplicity of miniature burners and $5 causing the individual flames or products of combustion to play upon chilled surfaces Whereon a portion of the carbon content is deposited and subsequently scraped off. The black thus obtained often contains metallic 40 iron and scale, is accompanied by burned particles of carbon and often contains other impurities and characteristics which render it unsuitable for certain of its uses. Moreover the apparatus usually employed is crude and comparatively expensive to build and the collecting devices wear very rapidly, necessitating periodic replacements. Furfor example 'termined pressures preferably only slightly ther the usual commercial plants are cumbersome and occupy large areas.

Certain other methods have been so gested for the manufacture of carbon blac but none of them appear to have reached the practical or commercial stage of development.

Accordingly to my improvements it produce a carbon of an improved character "which is peculiarly free from the above mentioned injurious constituents and undesirable characteristics, and moreover, ll obtain larger quantities of carbon er unit volume of gas and in a more efiicient and less expensive manner than is possible with known methods and devices.

Generally stated, my improvements reside in the continuous partial or incomplete combustion of the hydrocarbon gas in a comparatively large furnace by supplying to the furnace and to the gaseous flame predetermined quantities of air which are insufficient for complete combustion, and the passing of the resultant products of combustion through a suitable collector for isolating the liberated carbon therefrom.

I have found that the quality of the carbon ield are substantially improved by a care 111 and accurate adjustment of the mixture of air (oxygen containing agent) and gas supplied to the furnace, and particularly by the manner in which the mixture is accomplished. For example, the admission of the air into the furnace beneath the burners gives good results, par-' ticularly when the air is automatically supplied in regulated uantities and at prede above atmospheric). Fairly good results havebeen obtained by automatically mixing the gas and air according to predetermined proportions before the mixture reaches the flame zone, but I now refer to effect mixture by admission of t e air at points beneath the flame. This application is directed more particularly to methods and devices tending toward these ends as applied to the incomplete combustion of the gas and separation of the carbon as aforesaid. I prefer also to employ these methods and devices inconnection with certain other of my improvements in the manufacture of carbon as will appear herelnafter.

In the practice of my invention 1 have de vised a furnace with a battery of comparatively large burners or gas intakes with their mouths opening into the furnace at points a short distance from the bottom of the cham her, and with an air intake or intakes disposed below the level of the burners. The hydrocarbon gas issuing from the gas intakes is caused to burn very slowly and lazily by supplying thereto predetermined quantities of air, but insuflicient to produce complete combustion, the gas being supplied at a pressure above atmosphere and the burning taking place at the desired pressure. Means are provided for. regulating the pressure and the volume of the gas supplied to the burners and for automatically regulating and supplying the exact quantity of air required to the furnace. Preferably this means consists of a rotary fan or blower, as

good results have been obtained therewith. The resulting products of combustion and unburned gases are more or less confined or trapped in the furnace and the temperature thereof elevated to the desired degree for most eflicient operation. Provision is made for the gradual exhaust of the resulting products and gases through a restricted outlet near the top of the furnace. The hot products with the liberated carbon are conducted from this outlet through a cooling system or circuit of restricted dimensions for reducing the temperature increasing the density and reducing the vol ume and thence to a collector where the carbon is separated y from the other constituents. The collector is preferably either of the electrical precipitation type or of the closed bag filtration type. A fan or blow-er together with an exhaust regulator is provided for the purpose of assisting to maintain the natural draft of the products of combustion and to impart there to the required velocity through the restricted passages of the cooling system, as I find that the efiiciency of operation and production is thereby increased. This fan may be dispensed with, however. in cases where the desired draft is otherwise obtained. The hot gases with the liberated carbon in suspension are drawn through the conduits at suflicient velocity to carry along therewith the greater rtion of any floccu ent carbon which may b precipitated in the cooling pipes, and substantially the whole of the liberated carbon which leaves the furnace with the gases is borne to the collector and thence recovered.

' The advantages of my improved method and apparatus will more fully appear from the following'detail description-and the aceompanying drawin the latter being diagrammatic illustrations of the system and apparatus according to certain modifications, whereina I Figure l is a'diagrammatic drawing of a system embodying my improvements.

Figure 2 is a modification of the furnace and air intakes'illustrated in Figure 1.

Figure 3 is a diagrammatic drawing of a modification of the system shownin Figure 1.

Figure 4 is an illustration of a form of collector.

Referring to these drawings I have illustrated in section a furnace 1 this furnace being of large or generous dimensions as compared with certain of the other elements of the apparatus. There are provided a number of burners 2 (only two being illustrated) which are supplied with a hy,drocarbon gas, for example natural gas, through a supply pipe -3 leading to a gas main 4; A valve 5 is indicated for controlling the gas circuit and preferably the circuit is provided with a as pressure regulator (not illustruted) or the purpose of supplying gas at a substantially uniform and constant pressure. The furnace is preferably sealed modified 'against the entrance of air or other oxygen containing agent exce t through an air opening 6 through whic the air maybe admitted at a point below the level of the burners 2. A rotary fan or blower 7 is provided for positively supplying a predetermined and regulated quantity of air through the opening 6 and down below the burners 2. A regulator 8 is provided for adjusting the size of the opening 6 and'thereby enabling cooperation with the blower for effecting accurate control of the quantity of air supplied. This regulator may be of any conventional form, but is illustrated as of the shutter type by which means the air opening may be adjusted to the required area to give the exact quantity of air at atmospheric pressure desired. It is noted that the burners 2 are disposed near the bottom of the furnace apd that the'air openingfi is disposed 'pipe of restricted dimensions as compared to the volume of the furnace and a water spray system 13 which may continuously spray cold water upon the cooling pipes 10 for the pro purpose of reducin the temperature of the nets of com ustion passing therethrough. I The degree. of cooling may be regulated by adjusting the supply of water to the s raying system. as for instance by means 0 a valve 14 in the water main. The

cooling pipes 10 are observed to slightly diminish in cross section from the frontto the rearmost end. This reduction in cross section ma be made because the product of combustion may be reduced in volume as they are cooled by contact with the cooling pipes. The resulting increase in density of the gases passing through the cooling and collector system romotes the efficient separation of the car on from the other gases.

Two different types of collectors are illustrated, collector 12 being of the bag filtration type and collector 12' (Fig. 4) being of the electrical precipitationtype. The collector 12 consists generally of a container, preferably of cylindrical shape, with the hopper 15 on the lower part for collecting the carbon as it falls by gravity or is caused to fall from the filtration bags. The filtration bags are indicated diagrammatically at 16 whose open ends register with the openings 17 in the partition plate 18 carried by the container. The bags (only two of which are shown) may be carried in any suitable manner and means may be provided, if desired, for agitating or shaking the bags to loosen the carbon collected thereby. I have illustrated a novel chain arrangement for loosening the carbon.. The chain 19 being suspended from the bar 20 and the whole being mounted upon a crank 21 whereby the chains may be given the necessary movement for contacting with and jostling the bags.

The chains preferably are suspended to hang downwardly within the bags. I

A blower or exhauster 22 is provided for assistin the natural draft of the system, the blower being connected with the upper part of the collector container through a conduit 23. There is disposed-within this conduit a regulating valve 24 whereby the exhaust or draft pressure may be regulated or adjusted to a. nicety.

The operation of the system may be described substantially as follows:

The natural gas having been turned on (at a pressure above that of the atmosphere), the burners are lighted and the air regulator 8 and blower 7 adjusted to-supply positively the exact quantity of'air desired for the most efiicient operation of the systemand the products of combustion resulting from the incomplete combustion of the natural gas gradually accumulate in the furnace until the upper part thereof is completely filled with the gases and the liberated carbon in suspension. The main gate 25 in the circuit being open the products of combustion with the suspended liberated reeaeer the greater portion of flocculent carbon which is precipitated or becomes deposited J upon the inner walls of the cooling circuit is carried along with the main stream .of products ofcombustion into the collector so that the" great portion of the liberated carbon which leaves'the furnace through the outlet 9 actuallyreaches the collector and is there filtered out and deposited into the hopper 15, the cleansed gases pass out' through a conduit 23 and the blower 22.

I have foundthat the bag collectors 0perate very efficiently to filter out the liberated carbon and that they work particularly well at temperatures below 225 F. Eflicient results for example have been obtained with the operation of the collector ases at a temperature of 170 F. to 225".F l have also found that with the proper adjustment of the gas and air supplied to the ,furnace and with a proper balance of the system including the careful adjustment of the exhaust pressure and the degree of cooling that the carbon black recovered in the hop or 15 is a particularly desirable commercia product and is free from the above noted injurious constituents and undesirable qualities; moreover the ield of carbon per unit of gas is found to e greater than the yield of carbon produced by many known methods and devlces.

These results are noticeable to a certain degree under various conditions of operation, but are particularly marked with temperatures in the furnace running above 1200 F. For example, with temperatures in the furnace of 1400 F. to 1800 F. (as measured by pyrometer 28), and with careful adjustment of the air admitted into the furnace, both the yield and quality of carbon produced are ood. A test of the gases near the top of t e furnace with one adjustment showed a total absence of-free oxygen, a small ercentage (1.8%) of carbon monoxide (C and a larger percentage (7.7%) of carbon dioxide (CO Good results were obtained with adjustments giving other percentages of these gases. It is also observed that with an adjustment such that the products of combustion and inter mixed gases are all retained above the level of the burners 2, the yield and quality are good. For example, as indicated in Figure 1, there seems under certain conditions to be a clearand defined dividing line or blanket 29 between the gases 30 above and the 7 air below this line, and the air entering the furnace and collectin beneath this blanket is robably preheate to a certain degree be ore it enters the combustion and disassociation space. The increased yield of carbon per unit of gas at the higher temperature 0 oration is probably due to the cooperation of all the elements of my process and apparatus, althou h it may be due 1n part to some disassociation of the carbon and hydro n of unburned gas which may reach the iigh temperature regions of the furnace without being burned by the flame.

ter.

' upon a difi'erent theory of operation and re- .tors. 'ing and exhaust system the gases may be exactions taking place.

I have also found that the electrical precipitator cooperates to a particular degree with my other apparatus to produce a large yield of-carbon per unit of gas, although I now prefer for certain reasons the bag filtration system.

For the purpose of relieving the furnace 1 of the products of combustion or for other reasons an outlet 26 is provided and is dis- I posed near the top of the furnace, a door 27 being positioned upon the upper end of the pipe 26 for the urpose of opening or closmg the same. e heater 11 is in the nature of a steam chamber for preheating the cooled products of combustion before they enter the collectors. This may be desirable in certain cases to raise the temperature of the gases above the dew or vaporization points before they pass through the collec- By a proper adjustment of the coolpected to lose a portion of the water or vapor content and the elevation of the temperature above the dew point before passage the greater .portion of the water content through the collector and out with the cleansed gases as a water vapor.

In Figure 2 I have illustrated a modified form of'furna'ce construction and air distribution. According to this modification the.

ae'eaeei ings 32 through which the air may pass 11 wardly into the combustion zone from t e chamber beneath. The air is admitted to this chamber below the false bottom throu h chamber below the false bottom, the burners projecting upwardly therethrough.

In Figure 3 I have illustrated a modified system, the main difference being that in this case the air and gas are thoroughly intermixed according to predetermined proportions bcfore the same is sup lied to the burners 2. For this purpose have provided a rotary mixing machine which takes the gas from the gas machines 5 and mixes it with the air according to predetermined and adjusted proportions. The gas and air mixture thus efi'ected is forced through the supply pipe 3 to the burners 2. This arrangement is desirable in certain cases although I now prefer the system wherein the air is supplied in the required quantities directly to the combustion s ace of the furnace independently of the int owing gas. In each of the various forms of the invention a substantially uniform mixing of the hydrocarbon and fuel is obtained prior to, or in the early stages, combustion and the partial combustion reaction iscarried on under uniform conditions which may be adjusted to suit the characteristics peculiar to any type of hydrocarbons which may be used in the production of the car bone. The disturbing influence of cooling plates, unguarded inflow of air and other In accordance with the requirements of l the patent statutes I have set forth only one form of the many forms my invention is through the collector insures the passage of capable of assuming. The drawings being purposely diagrammatic for convenience-in illustration, and it is understood that the claims, annexed hereto are not to be construed as limited to the exact methods and devices illustrated, except as is specifically recited therein, but are to be construed to cover all modifications coming within the spirit of the invention.

I claim:

1. An apparatus for producing carbon which comprises a furnace having a free,

spacious, combustion chamber, means for supplying air and gas to said furnace, means for intimately mixing said air and gas and thereafter burning said mixed gases in a manner to form free carbon, said furnace being free from heat abstracting or heat utilizing means.

2. An apparatus for producing carbon which comprises a furnacehaving a free, spacious, combustion chamber, means for supplying air and gas to said furnace, and means for mixing said air and gas and thereafter burning said mixed gases in a manner to form a suspension of free carbon in said gases said furnace being free from heat abstracting or heat utilizing means.

3. A process. of producing carbon which comprises diffusing air insufficient for complete combustion and hydrocarbons into intimate contact to form a substantially uniform mass of gas and burning said diffused mass in a freely and uniformly moving mass. g

4. In an apparatus for separating and recovering carbon black from a hydrocarbon gas, the combination of a furnace having a spacious combustion chamber together with gas burners adapted to receive and partially burn the gas in a freely flowing mass by the supply thereto of air in quantities insufficient for complete combustion, means for supplying to said furnace and burners predetermined quantities of air, and a cooling and collecting system for receiving the resultant products and means for positively supplying air to said furnace.

5. In an apparatus for separating and recovering carbon black from a hydrocarbon, the combination of a furnace arranged to permit a free unobstructed flow of burning gases together with burners adapted to receive and partially burn the hydrocarbon by the supply thereto of air in quantities insufficient for complete combustion, means for supplying the hydrocarbon to said burnjers, means for positively furnishing to said burners and said furnace predetermined quantities of air, and a collecting system wherein the resultant products are passed at a comparatively high velocity.

6. In an apparatus for separating and recovering carbon black from a hydrocarbon, the combination of a furnace arranged to permit a free unobstructed fiow of burning gases, a burner for receiving the hydrocarbon and partially burning the s'ame, a device for supplying a predetermined proportion of air to the burners for the purpose set forth, and means for cooling the resultant products and isolating the liberated carbon content.

7. In an apparatus coverin carbon from a hydrocarbon gas, the com ination of a furnace arranged to for separating and regases and burners adapted to receive and partially burn the gas, a rotary-blower and regulating means for supplying to the furnace and to the burners predetermined nantities and proportions of air, and a co lecting system for receiving the resulting products of combustion from the furnace and isolating the liberated carbon therefrom.

8. In an apparatus for separating and re-. covering carbon black from ahydrocarbon gas, the combination of a furnace arranged to permit a free unobstructed flow of burning gases, a burner adapted to receive and partially burn the gas, a rotary blower and regulating means for supplying to said burner predetermined proportions and quantities of air, and a cooling and collecting system for receiving the resulting prod- ,ucts of combustion from the furnace and isolating the liberated carbon therefrom.

9. In an apparatus for separating and recovering carbon black from a hydrocarbon gas, the combination of a furnace with burners in the lower portion thereof for receiving and partially burning the gas, a rotary blower for supplying predetermined proportions and quantities of air to said furnace at a point or points below the level of said burners, and means for subjecting the resulting products of combustion to a carbon isolating process.

10. In an apparatus for separating and recovering carbon black from a hydrocarbon gas, the combination of a furnace with a burner therein adapted to receive and partially burn the gas, means for admitting regulated quantities of air to said furnace at a point or points below the level of the burner, and means for subjecting the result ing products of combustion to a carbon isolating process.

11. In an apparatus for separating and recovering carbon black from a hydrocarbon gas, the combination of a furnace with burners disposed in the lower part thereof, a rotary blower with regulating means adapted to supply predetermined quantities and proportions of air to said furnace at a point or points below the level of the burners, and a collecting system adapted to receive the products of combustion and isolate the liberated carbon therefrom.

12. In an apparatus for separating and recovering carbon black from a hydrocarbon gas, the combination of a furnace with burners disposed in the lower part thereof adapted toreceive and partially burn the gas, a rotary blower with regulating means adapted to supply predetermined quantities and proportions of air to the furnace and the burners, a coolin system of restricted dimensions throu h WlllCh the products of combustion are a apted to pass, a collector adapted to permit a. free unobstructed flow of burning Q5 receive the cooled products and isolate the liberated carbon, and means for-'establishing the circulation of the products of combustion from the furnace and through the cooling and collecting system.

13. In an apparatus for separating and recovering carbon black from a hydrocarbon gas, a furnace having a false bottom and an air chamber therebeneath, and burners dis- 10 posed above the false bottom.

weasel recovering carbon black from a hydrocarbon as, a furnace having-gas burners disposed in the lower part thereof said furnace havmg a false bottom 'ust below the level of the burners and said also bottom being perforated'for admitting air from beneath the false bottom to and around the zones of the 1 burners for the purpose set forth.

In testimony whereof, I afiix my signature. 2

CIIAUNCEY MATLOCK. 

